Asra'Ul Hasibin Fahmi, Muhammad (2021) Upaya Meminimasi Defect Produk Side Frame Pada Kereta Barang Menggunakan Metode DMAIC. Sarjana thesis, Universitas Brawijaya.
Abstract
PT Barata Indonesia merupakan industri manufaktur yang bergerak di bidang pengecoran logam. Salah satu produk yang dihasilkan yaitu side frame. Proses produksi masih terdapat beberapa permasalahan seperti masih adanya produk yang mengalami defect karena pengendalian kualitas masih dilakukan secara umum dan belum rinci. Penelitian ini dilaksanakan menggunakan metode DMAIC dari program Six Sigma dengan tujuan untuk mengetahui penyebab terjadinya defect produk. Berdasarkan hasil penelitian, diketahui critical to quality pada produk side frame, kemudian untuk hasil perhitungan DPMO diperoleh nilai 71851 dan sigma level 4.0874. Berdasarkan hasil analisis fishbone dilajutkan analisis penyebab potensial pada produk cacat menggunakan Failure Mode and Effect Analysis (FMEA). Proses untuk menentukan nilai RPN yang digunakan untuk memberikan rekomendasi perbaikan. Beberapa rekomendasi perbaikan yang dapat diberikan pada produksi yaitu membuat checksheet dan papan peringatan untuk proses cetak dan coating, memberikan SOP pada proses cetak, memodifikasi mesin kompresor tiup menjadi sedot, dan melakukan preventive maintenance mesin hopper.
English Abstract
PT Barata Indonesia is a manufacturing industry engaged in foundry. One of the products produced from the foundry factory is the freight train bogie, where one of the main components is the side frame. In the production process itself, there are still several problems in identifying defects in products, the company is only limited to recording the type of defect and the form of the defect without any in-depth analysis. In this study, the DMAIC method from Six Sigma was carried out, the aim was to find out the causes of defects in the product and provide recommendations for improvement to minimize the number of existing defects. In this research, the first thing to do is take data in the field and study literature to determine the problem and purpose of conducting research. Then proceed with data processing. The DMAIC method consists of five stages, namely define, measure, analyze, improve, and control, for the first stage, which is to define or identify the cause of defects in the product using SIPOC diagrams and identification of Critical to Quality (CTQ). The second stage is measure, namely collecting and measuring data, as well as calculations using control charts, calculating DPMO values, process capabilities, and sigma levels. Next is the analyze stage by analyzing using fishbone diagrams to determine the factors that cause failure and FMEA calculations with weighting criteria on severity, occurrence, and detection to get the final value in the form of RPN. The fourth stage is improve, at this stage is to optimize by providing recommendations for improvement during the side frame production process. Then the control stage, but this stage was not carried out because the research took quite a lot of time, and finally conclusions and suggestions were drawn. Based on the results of this study, it can be seen that the CTQ on the side frame product is inclusion defects where the product surface does not have hollows, the product surface pinhole defects do not have round holes, and positive surface defects where the product surface does not have protrusions. Then for the DPMO value obtained a value of 71851, and the sigma level is 2.96. Based on the results of the fishbone diagram, it was found that the causes of failure were the cleaning of the molds was too fast, the mold cleaning method was less than optimal, the hopper machine did not sieve the sand properly and had a RPN value, the paint coating was not dry enough, the drying during the coating process was not optimal, and the coating drying method was lacking, the cleaning method the mold is less than optimal, and does not pay attention to the presence of clumps/concave in the mold that is less clean. After that, look for potential causes of defects with Failure Mode and Effect Analysis (FMEA) with the highest RPN results and then determine recommendations for improvement. The recommendations for improvement include, making warning boards and checklist forms for cleaning and coating drying times as well as checklist forms for cleaning times on molds, providing assessment and training to workers, making SOPs for workers in the mold cleaning process, modifying blow compressor machines to suction, and lastly. Perform preventive maintenance on the hopper engine.
Other obstract
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| Item Type: | Thesis (Sarjana) |
|---|---|
| Identification Number: | 670 |
| Uncontrolled Keywords: | Defect, DMAIC, Six Sigma, CTQ, DPMO, SIPOC, FMEA, Side Frame. |
| Subjects: | 600 Technology (Applied sciences) > 670 Manufacturing |
| Divisions: | Fakultas Teknik > Teknik Industri |
| Depositing User: | Unnamed user with email gaby |
| Date Deposited: | 21 Oct 2021 08:27 |
| Last Modified: | 25 Feb 2022 06:33 |
| URI: | http://repository.ub.ac.id/id/eprint/184741 |
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